Continuous-stream upflow zeolite crystallization apparatus

Abstract

A continuous-stream zeolite crystallization apparatus comprising a combination of a tubular reactor, a central stirring element contained therein, ingress and egress means for the reactor for charging crystalline zeolite forming reactants therein and recovering crystallized zeolites therefrom, respectively, recovery vessels for collecting and processing crystallized zeolites continuously, the reactor and recovery vessels optionally being subjected to a controlled pressure system.

What is claimed is: 
     
       1. An apparatus for preparing crystalline zeolite materials on a continuous stream basis comprising a substantially vertically-oriented reactor means,   a stirring means inside said reactor means, said stirring means being operatively associated with said reactor means and comprising an elongated rod means having a plurality of blades angularly disposed about said rod means,   said stirring means extending substantially throughout the entire length of said reactor means,   a first and a second reactants entrance means in the lower portion of said reactor means,   said first reactants entrance means being positioned on the opposite side of said reactor means than said second reactants entrance means,   said first reactants entrance means continuously conveying a source of silica into said reactor means,   said second reactants entrance means continuously conveying a source of alumina ions into said reactor means,   at least one product exit means in the upper portion of said reactor means for continuously removing crystalline zeolite product from said reactor means,   a multitude of baffle means on the inside surface of said reactor means, said baffle means being disposed angularly with respect to said inside surface of said reactor means and being spaced in such a manner that said baffle means are interspaced in-between said blades of said stirring means,   said angularly disposed blades, said baffle means and said first and second reactants entrance means positioned on the opposite sides of said reactor means cooperating in advancing the reactants upwardly and preventing plugging of the first and second reactants entrance means by the crystalline zeolite materials,   a heating means surrounding said reactor means, and   a pressurizing means for pressurizing said reactor means with an inert gas.   
     
     
       2. An apparatus according to claim 1 wherein said at least one product exit means comprises a first product exit means connected to a first crystalline zeolite product collecting means, and   a second product exit means connected to a second crystalline zeolite product collecting means.   
     
     
       3. An apparatus according to claim 2 wherein said first and said second product exit means are each connected to said first and to said second crystalline zeolite product collecting means, respectively, by means of a conduit containing a valve means. 
     
     
       4. An apparatus according to claim 3 wherein said inert gas is helium, nitrogen, and/or steam. 
     
     
       5. An apparatus according to claim 4 wherein the reactor is cylindrical in shape. 
     
     
       6. An apparatus according to claim 5 wherein the ratio of the length of the reactor to its diameter is at least 3. 
     
     
       7. An apparatus according to claim 6 wherein the ratio of the length of the reactor to its diameter is 4 to 36. 
     
     
       8. An apparatus according to claim 7 wherein said second reactants entrance means also continuously conveys a source of nitrogen ions into said reactor means. 
     
     
       9. An apparatus according to claim 8 wherein said source of nitrogen ions is tetrapropyl ammonium bromide. 
     
     
       10. An apparatus according to claim 9 wherein said blades are disposed about said rod means at between 30° to 60°. 
     
     
       11. An apparatus according to claim 10 wherein said blades are disposed about said rod means at about 60°.